Lanyard Coupler, System and Method

ABSTRACT

A lanyard coupler for selective attachment to a lanyard strap and an attachment member, the lanyard coupler including a body having a first end and a second end, an arm portion being formed toward the first end, the body tapering from the first end toward the second end. A strap receiving opening extends across a portion of the body, while a connector extends from the second end of the body.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claim priority to and benefit of U.S. Provisional Patent Application No. 62/724,334, filed 29 Aug. 2018, and entitled LANYARD COUPLER WITH SONIC WELDING ATTACHMENT, the disclosure of which is incorporated herein by reference.

BACKGROUND OF THE INVENTION 1. The Field of the Invention

The present invention is in the field of lanyards. More specifically, the present invention relates generally to systems, methods, and apparatus for coupling items to lanyards.

2. Background and Relevant Art

A lanyard is a cord, strap, line or other such member used to hold or fasten to an object. Lanyards are commonly worn by persons to secure items around their neck or body. One end of the lanyard typically includes a connector and/or clip to which the items can be attached, such as name tags, wallets, keys, lip balm, or any other personal item. A variety of different lanyards and lanyard connectors are presently available within the art.

A number of presently available lanyards and lanyard connectors utilize multiple separate component parts that are assembled together through many steps, some of which are difficult to perform and can result in assembler fatigue. This results in an increase in manufacturing time and the likelihood of error or manufacturing difficulties. Furthermore, using multiple separate components parts results in a more unwieldy or cumbersome lanyard or lanyard system. As such, there are a number of disadvantages in the art that can be addressed.

BRIEF SUMMARY OF THE INVENTION

Implementations of the present invention solve one or more problems in the art with systems, methods, and apparatus for coupling items to lanyards. In particular, the present invention relates to a lanyard system having a lanyard coupler that receives a lanyard at one end and is selectively attachable or mountable to an attachment member on the other end. A lanyard coupler can include a body having a first end and a second end, an arm portion being formed toward the first end, with the body tapering from the first end toward the second end. A strap receiving opening extends across a portion of the body, while a connector extending from the second end of the body. Optionally, the arm portion can have a generally gooseneck shape with a hook portion.

In another configuration, the lanyard system includes a coupler having a body with an elongate slit extending across at least part of the body near a proximal end, the slit forming a proximal arm portion extending across the body proximal to the elongate slit. A connector extends away from the distal end of the body. The lanyard strap received within the slit has a weld that secures at least three layers of the lanyard strap together, thus forming a loop at a distal end of the lanyard strap.

In still another configuration, the lanyard system can be formed through an assembly method that includes providing a coupler and providing a lanyard strap. The coupler includes a lanyard strap receiving opening extending across a body near a proximal end of the body, the lanyard strap receiving opening forming an arm portion at the first end of the body. The lanyard strap has a loop formed by overlapping portions of the strap substrate and then forming a weld or welding the overlapping portions together, such as through a thermal or ultrasonic welding process. With the provided coupler and strap, the method includes attaching the lanyard strap to the coupler by inserting the lanyard strap into the lanyard strap receiving opening so that the lanyard strap passes through the lanyard strap receiving opening and the arm extends through the loop.

In another configuration, the arm portion of the coupler is connected to a body portion at a first side of the body and separated at a second side of the body. In so doing, the arm portion can extend in a cantilever fashion from a remainder of the body and form the lanyard strap receiving opening. Optionally, repeated protrusions or a roughened surface can be formed along all or a portion of the walls forming the lanyard strap receiving opening and so can surround the lanyard strap receiving opening.

In another configuration, a perimeter of the coupler includes a chamfer or tapered edge. The chamfer or tapered edge can extend along an entire length of the perimeter or along only a discrete portion of the perimeter, such as along all or a portion of the lanyard receiving opening, along all or a portion of the outer surface of the body, or some other combination.

In another configuration, the lanyard strap receiving opening can include a first opening portion and a second opening portion, the first opening portion having a first terminal end having a generally curved profile and a second terminal end terminating toward the second opening portion. The second opening portion can extend angularly from the first opening portion. Optionally, the second opening portion can have a first portion and a second portion, the first portion and the second portion being inclined relative to a longitudinal axis of the body at different inclinations. In another configuration, the first portion can extend from the first opening portion and the second portion extends from the first portion, the first portion being generally parallel to the longitudinal axis and the second portion being transverse to the longitudinal axis.

In still another configuration, the first portion and the second portion of the second opening portion can include at least one lip or protrusion, such as adjacent a junction of a first portion and a second portion forming the lanyard receiving opening. The at least one lip can form a narrow portion to the passageway of the second opening portion.

Additional features and advantages of exemplary implementations of the invention will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by the practice of such exemplary implementations. The features and advantages of such implementations may be realized and obtained by means of the instruments and combinations particularly pointed out in the appended claims. These and other features will become more fully apparent from the following description and appended claims or may be learned by the practice of such exemplary implementations as set forth hereinafter.

BRIEF DESCRIPTION OF THE DRAWINGS

In order to describe the manner in which the above-recited and other advantages and features of the invention can be obtained, a more particular description of the invention briefly described above will be rendered by reference to specific embodiments thereof which are illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments of the invention and are not therefore to be considered to be limiting of its scope, the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:

FIG. 1 illustrates a lanyard strap secured to a lanyard coupler according to an implementation of the present disclosure;

FIG. 2 illustrates a lanyard strap secured to a lanyard coupler according to an implementation of the present disclosure, with an attachment rotatably coupled to the lanyard coupler;

FIG. 2A illustrates a side view of the lanyard strap according to an implementation of the present disclose;

FIG. 3A is a top plan view of the lanyard coupler of FIG. 1;

FIG. 3B is a bottom plan view of the lanyard coupler of FIG. 1;

FIG. 3C is side view of the lanyard coupler of FIG. 1;

FIG. 3D is another side view of the lanyard coupler of FIG. 1;

FIG. 3E is a rear end view of the lanyard coupler of FIG. 1;

FIG. 3F is a front end view of the lanyard coupler of FIG. 1;

FIG. 4 is a close-up view of a portion of the lanyard coupler of FIG. 1;

FIG. 5A is a top plan view of another lanyard coupler according to an implementation of the present disclosure;

FIG. 5B is a bottom plan view of another lanyard coupler according to an implementation of the present disclosure;

FIG. 5C is side view of another lanyard coupler according to an implementation of the present disclosure;

FIG. 5D is another side view of another lanyard coupler according to an implementation of the present disclosure;

FIG. 5E is a rear end view of another lanyard coupler according to an implementation of the present disclosure;

FIG. 5F is a front end view of another lanyard coupler according to an implementation of the present disclosure;

FIG. 6 is a close-up view of a portion of another lanyard coupler according to an implementation of the present disclosure; and

FIG. 7 is a perspective view of a lanyard strap secured to a lanyard coupler of FIG. 1.

FIG. 8 is a perspective view of an intermediate coupler according to an implementation of the present disclosure.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

One or more specific embodiments of the present disclosure will be described below. In an effort to provide a concise description of these embodiments, some features of an actual embodiment may be described in the specification. It should be appreciated that in the development of any such actual embodiment, as in any engineering or design project, numerous embodiment-specific decisions will be made to achieve the developers' specific goals, such as compliance with system-related and business-related constraints, which may vary from one embodiment to another. It should further be appreciated that such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure.

One or more embodiments of the present disclosure may generally relate to manufacturing and using lanyard systems. A lanyard system may allow individuals to securely retain personal items, such as name tags, wallets, keys, lip balm, or any other personal item. For instance, personal items can be retained by attachment members that are in-turn coupled to a lanyard coupler and a lanyard strap of the lanyard system. The lanyard coupler described herein provides an easy to use coupler to which a user can conveniently couple a lanyard strap. The coupler, and the strap itself, is simple to manufacture to allow interchangeability of couplers, straps, and attachment members. This offers a system that conveniently accommodates a variety of different attachments, straps, and couplers.

While the present disclosure will describe a particular implementation of the lanyard system, it should be understood that the devices, systems, and method described herein may be applicable to uses. Additionally, elements described in relation to any embodiment depicted and/or described herein may be combinable with elements described in relation to any other embodiment depicted and/or described herein.

Referring now to the FIG. 1 illustrated is a lanyard system 8 that includes a lanyard substrate or strap 10 secured to a lanyard coupler 12, which in-turn cooperates with an attachment member 14. For purposes of the present disclosure, a proximal end or direction denotes portions of the coupler and/or strap that are closer to the user's neck when the strap is worn thereabout, and a distal direction refers to portions further away from the neck of the user. For example, as seen in FIG. 1, a distal end 16 of the strap 10 is shown secured to a proximal portion 18 of the coupler 12, while the attachment member 14 cooperates with a distal portion 20 of the coupler 12 as shown in FIG. 2, which will be discussed in greater detail hereinafter.

The strap 10 extends from the coupler 12 and receives a portion of the coupler 12 within a loop 22 at the distal end 16 of the strap 10 so that at least a portion of the strap 10 overlaps a portion of the coupler 12 when it is received within the loop 22. The loop 22 is formed by overlapping portions or layers of the strap 10, with three layers of strap 10 being joined together in the configuration illustrated in FIG. 1. A single elongate length of lanyard substrate forms the loop 22 and also a loop 122 receiving the user's neck (see FIG. 7). While three layers of strap 10 are joined together in the illustrated configuration, one skilled in the art would understand that two or more layers can be overlapped to form one or more loops depending upon the particular needs of the strap 10. For instance, if the strap were to include two loops, four or more layers could be joined together.

FIG. 2A depicts the strap 10 overlapping itself to form the loop 22. As illustrated in FIG. 2A, a first end portion 24 of the strap 10 is positioned between the second end portion 26 of the strap 10 and an intermediate portion 28 of the strap 10, in a direction transverse to a direction in which the intermediate portion 28 extends to form the loop 122 receiving the user's neck (see FIG. 7). For instance, the first end portion 24, the second end portion 26, and the intermediate portion 28 overlap in a direction A, while the intermediate portion 28 extends in direction B.

In the illustrated embodiment of FIG. 2A, the first end portion 24, the second end portion 26, and the intermediate portion 28 are joined together to form the loop 22 at the joint region 30. When the substrate for the strap 10 is formed of a polyester, nylon, or other thermoplastic polymer and composite the joint region 30 is a weld. The weld can be formed in a number of ways, including, but not limited to, the use of ultrasonic welding, melt welding, or the like. Alternatively, or in addition to welding, the joining of the layers of the strap 10 at the joint region 30 can be achieved through adhesives, stitching or other mechanical fasteners, such as when the strap 10 is formed of a material other than thermoplastic polymers and composites. The use of welding, however, beneficially decreases manufacture time and increases manufacture productivity by providing a simple and repeatable approach to forming the loop 22 and, more generally, the strap 10 of the lanyard system 8.

Returning to FIG. 1, the lanyard coupler 12 has a substantially flat body 40 which can lay in a relatively flat fashion when the strap 10 and the coupler 12 are worn by a user. A body 40 of the coupler 12 has a first proximal end 42 and a second distal end 44, with the body 40 tapering from the first proximal end 42 towards the second distal end 44. A strap receiving opening 46 extends across a portion of the body 40 and separates the body 40 into an arm portion 50, which can be received within the loop 22 of the strap 10, and a body portion 52 from which extends a connector 54 that allows convenient connection to many different attachments, such as attachment member 14 and attachment 14′ (FIG. 7). The attachment 14 is illustrated in a detached orientation in FIG. 1 and an attached orientation in FIG. 2. The attachment member 14 is a clip-like attachment, while the attachment member 14′ is a loop-like or ring-like attachment (See FIG. 7). The discussion related to the attachment member 14 is also applicable to the attachment member 14′ (See FIG. 7). Additionally, instead of connecting directly to the attachment member 14, the coupler 12 can attached to an intermediate adapter 130 (see FIG. 8) disposed between the attachment member 14 and the coupler 12. This intermediate adapter 130 can increase a separation distance between the attachment member 14 and the coupler 12, thereby providing alternate user access to the item held by the attachment member 13, such as name tags, wallets, keys, lip balm, or any other personal item.

With continued reference to FIG. 1, the connector 54 extends from the second distal end 44 of the coupler 12. As illustrated, in proximity to a location from which the connector 54 extends, the body 40 includes reinforcement portions 68 that provide additional structural support to the distal end 44. A reinforcement portion 68 is formed on either side of the body 40, although only one reinforcement portion 68 may be include in alternate configurations. Reference will be made to one of the reinforcement portions, however, the discussion is also applicable to the other reinforcement portion.

The reinforcement portion 68, as illustrated in FIGS. 1 and 3A-3F, is a raised portion elevated in relation to a generally planar surface 48 of the outer surface of the body 40. A surface of the reinforcement portion 68 curves towards a first side 64 and a second side 66, while also curving from the distal end 44 towards the proximal end 42. A transition 78 between the reinforcement portion's surface and a remainder of the body 40 has a generally semicircular form, however, other shapes or forms of transition can be used. For instance, transitions having other curved non-semicircular forms or other non-curved forms of are possible. Additionally, while the transition 78 terminates distal the strap receiving opening 46 in a distal-to-proximal direction, in alternate configurations, at least a portion of the transition 78 is coincident or corresponds to an inner edge of the strap receiving opening 46 in the distal-to-proximal direction. Similarly, while the transition 78 terminates remotely from the first side 64 and the second side 66 in a direction transverse to the distal-to-proximal direction, in other configurations the transition 78 can be the first side 64 and/or the second side 66.

Returning to FIG. 1, the connector 54 is configured as a male portion of a male/female connection between the connector 54 and the attachment member 14. The connector 54 is removably connected to a complementary female portion of the attachment member 14. The connector 54 may, for example, be secured to an item that can then be selectively and removably connected to the coupler 12 shown. Other embodiments of the connector 54 may include other male and/or female connection types that enable the coupler 12 to be removably connected to items having complimentary connections secured thereto.

The connector 54 has two spaced apart members 56 a, 56 b that collectively form the connector 54 to which the attachment member 14 can be selectively coupled and about which the attachment member 14 can selectively rotate. The members 56 a, 56 b flex inwardly when being mounted to a base 70 of the attachment member 14, then flex outwardly to maintain (e.g., temporarily) the members 56 a, 56 b within the base 70. It is possible to detach the attachment member 14 from the coupler 12 upon applying sufficient force to move the parts apart e.g., by bending or otherwise manipulating the coupler 12 with respect to the attachment member 14 and pulling the parts apart.

Each member 56 a, 56 b includes a narrow portion 58 a, 58 b and an enlarged portion 60 a, 60 b. The narrow portion 58 a, 58 b has a generally semicircular cross-section, while the enlarged portion 60 a, 60 b tapers from the narrow portion 58 a, 58 b toward an end 62 of the connector 54. The generally semicircular cross-section allows rotational movement of the attachment member 14 relative to the coupler 12, aiding with comfortable positioning of the coupler 12 and an item supported by the attachment member 14 for the user.

With reference to FIGS. 1 and 2, in one embodiment, the base 70 of the attachment member 14 includes an interior diameter portion 72 that is complementary to the connector 54. For instance, the interior diameter portion 72 of the base 70 is tapered to allow convenient mounting of the attachment member 14 onto the connector 54. The interior diameter portion 72 can, however, be non-tapered.

Slot 74 a, 74 b are formed in the base 70 thereby forming locking rim 76 a, 76 b to which the enlarged portions 60 a, 60 b contact as they flex outwardly. A portion of each enlarged portion 60 a, 60 b enters a respective one of the slots 74 a, 74 b so that a proximally facing portion of the enlarged portions 60 a, 60 b overlap with and engage with the locking rims 76 a, 76 b to prevent inadvertent detachment of the attachment member 14 from the connector 54 of the coupler 12. However, as mentioned above, it is possible to detach the attachment member 14 from the coupler 12 upon applying sufficient force to move the parts apart e.g., by bending or otherwise manipulating the coupler 12 with respect to the attachment member 14 and pulling the parts apart, causing the members 60 a, 60 b to move off the locking rims 76 a, 76 b and out of the base 70.

Turning to FIGS. 3A-3F and 4, illustrated is one embodiment of the coupler 12 with the strap receiving opening 46 positioned between the arm portion 50 and the body portion 52. The arm portion 50 is partially separated from the body portion 52 by the strap receiving opening 46. Stated another way, the arm portion 50 extends from the body portion 52 in a cantilever fashion with the strap receiving opening 46 being disposed between the arm portion 50 and the body portion 52. The arm portion 50 is connected to the body portion 52 on a first side 64 and separated from the body portion 52 on the second side 66. The arm portion 50 and the body portion 52 defining the form and configuration of the strap receiving opening 46. For instance, with the arm portion 50 having an elongate portion 80 and a hook portion 82, thereby forming a generally gooseneck shape, and the body portion 52 having a complementary form, the strap receiving opening 46 provides a space into which the strap 10 can be inserted and secured to the coupler 12, as illustrated in FIG. 4. It will be understood, however, that the arm portion 50 can have other forms and shapes and the body portion 52 can have complementary and non-complementary forms that provide strap receiving openings of different forms or shapes while still providing a space for securely retaining the strap 10.

The strap receiving opening 46 includes a first opening portion 90 and a second opening portion 92. The first opening portion 90 has a first terminal end 94 and a second terminal end 96 terminating toward the second opening portion 92. The first opening portion 90 extends horizontally at least partially across a body 40 of the coupler 12 at or near the first proximal end 42 of the coupler 12. In the illustrated configuration, each of the first terminal end 94 and the second terminal end 96 have a curved profile to accommodate the edges of the strap 10. For instance, to aid with retaining in the strap 10 within the strap receiving opening 46, an edge 32 of the strap 10 fits within the curved profile to provide a tight fit and limit lateral movement of the strap 10 relative to the coupler 12. While the curved profile can approximate the size and dimension of the strap 10 and edge 32, it will be understood by one skilled in the art that in other configurations the curved profile need not approximate the strap 10 and edge 32.

Extending from the first opening portion 90 is the second opening portion 92, as illustrated in FIG. 4. The second opening 92 extends away from the first opening portion 90 as a passageway or angled passageway that communicates with the first opening portion 90 and a perimeter 98 of the body 40. The second opening portion 92 allows access to the first opening portion 92 into which the strap 10 is inserted, while the orientation of the second opening prevents inadvertent removal of the strap 10 from the first opening portion 92.

As illustrated, the second opening portion 92 includes a first portion 100 and a second portion 102 that is slanted relative to the first portion 100. The first portion 100 can also be inclined relative to the first opening portion 90 or can be perpendicular to the first opening portion 90. Stated another way, the combination of the first portion 100 and the second portion 102 forms an angled passageway that extends from the first opening portion 92 in a proximal-to-distal direction, i.e., downwardly. Alternatively, the combination of the first portion 100 and the second portion 102 forms an angled passageway that extends from the first opening portion 92 in a distal-to-proximal direction, i.e., upwardly. In either case, the first portion 100 can be transverse to the first opening portion 90 (such as transverse to an axis extending in the proximal-to-distal direction, such as a longitudinal axis) or perpendicular to the first opening portion 90 (such as parallel to the axis extending in the proximal-to-distal direction, such as the longitudinal axis) and the second portion 102 can be transverse or perpendicular to the first portion 100, which results in the second portion being transverse to or perpendicular to the axis extending in the proximal-to-distal direction, such as a longitudinal axis.

To form the first portion 100 and the second portion 102, the arm portion 50 includes a wall 110 extending from the second terminal end 96 and a wall 112 that is slanted relative to the first wall 110. The junction of the wall 110 and wall 112 forming a lip 118 that provides resistance to a movement of the strap 10 out of the strap receiving opening 14. Similarly, the body portion 52 includes a wall 114 extending from the first opening portion 90 and a wall 116 that is slanted relative to the wall 114. The walls 110, 114 define a perimeter of the first portion 100 of the second opening portion 92, while the walls 112, 116 define a perimeter of the second portion 100 of the second opening portion 92.

The embodiment of FIGS. 3A-3F and 4, the coupler 12 has a smooth transition between the walls 110, 112 and so the lip 118 so that the second opening portion 92 between the wall 110 and wall 112 and between the wall 114 and 116 form a generally uniform cross-section. Stated another way, the passageway of the second opening portion 92 has a generally uniform cross-section along its length. It will be understood, however, that the slant of the walls 110-114 can vary so that the second opening portion 92 can have different configurations. For instance, as illustrated in FIGS. 5A-5F and 6, the lip 118′ of the coupler 12′ is more pronounced than the lip 118 and extends inwardly towards the body portion 52′, thereby narrowing the second opening portion 92′ at a location closer to the first opening portion 90′ as compared with a location of the second opening portion 92′ closer to the perimeter 98′. The second opening portion 92′, therefore, tapers from the first opening portion 90′ to the perimeter 98′.

A lip 124′ is formed across the second opening portion 92′ from the lip 118′. The combination of the lip 118′ and the lip 124′ collectively narrows the second opening portion 92′ close to the first opening portion 90 to prevent the strap 10 becoming inadvertently detached from the coupler 12′. It will be understood, that in other embodiments, the coupler can include only the lip 118′ or only the lip 124′, rather than both lips. The second opening portion 92′ can be narrowed by about 35 percent to about 40 percent as compared to the end of the second opening portion 92′ at the perimeter 98′ of the body 40′ by the lip 118′, the lip 124′, or a combination of the lip 118′ and the lip 124′. Alternatively, the second opening portion 92′ can be narrowed by about 10 percent to about 90 percent, by about 20 percent to about 80 percent, by about 30 percent to about 70 percent, by about 65 percent to about 90 percent, by about 20 percent to about 35 percent, by about 40 percent to about 65 percent, or by about 10 percent to about 20 percent.

While the embodiments illustrated in FIGS. 5A-6 include the lip 118′ and the lip 124′ near the junction between the first opening portion 90′, it will be understood that one or both of the lip 118′ and the lip 124′ can be disposed part way along the second opening portion 92′. This provides an alternate manner to limit the possibility of the strap 10 becoming dislodge or exiting the second opening portion 92′ because it has to pass two differently positioned lips and move in two different directions, i.e., past one lip towards the side of the coupler and then move past the other lip in a direction away from the side of the coupler. The lip 118′, therefore, can be closer to the perimeter 98′ than to the first opening portion 90′ or the lip 124′ can be closer to the perimeter 98′ than to the first opening portion 90′.

Additionally, while reference is made to the lip 118′ and the lip 124′ being opposite to each other across the second opening portion 92′, the lip 118′ and the lip 124′ can be offset from each other along the second opening portion 92′. This results in the second opening portion 92′ has a serpentine, bending, tortuous, or twisting form. For instance, with the lip 118′ near the first opening portion 90′ the lip 124′ is closer to the perimeter 98′ than the lip 118′ to form the serpentine, bending, tortuous, or twisting second opening portion 92′. Similarly, with the lip 124′ near the first opening portion 90′ the lip 118′ is closer to the perimeter 98′ than the lip 124′ to form the serpentine, bending, tortuous, or twisting second opening portion 92′.

In addition to the couplers 12, 12′ described and shown herein, one or more embodiments of a coupler 12 can also include one or more protrusions 120 within the strap receiving opening 46, including one or both of the first opening portion 90 and the second opening portion 92. For example, a plurality of repeated protrusions 120, or “teeth,” can be formed along the inside edge or edges of the strap receiving opening 46. The protrusions increase the surface area and frictional contact between the strap 10 and the inside edge or edges of the strap receiving opening 46 to form a more secure connection therebetween. The protrusions can be any number or combination of shapes, including triangular or semicircular protrusions that run along the inside edge or edges of the strap receiving opening 46. Alternatively, all or portions of the strap receiving opening 46, and more generally the body 40, can be roughened or textured to change the frictional engagement between the coupler 12 and the strap 10. Stated another way, all or portions of the strap receiving opening 46, and more generally the body 40, can receive a surface finish to provide desired frictional engagement between the coupler 12 and the strap 10 and/or the coupler 12 and the attachment member 14. For instance, a surface finish to aid with rotational movement of the attachment member 14 about the connector 54 can be applied to one or both of the attachment member 14 and the connector 54, such as applying a TEFLON coating or other low friction coatings. Alternatively, to prevent unwanted movement between the strap 10 and the coupler 12, an appropriate surface finish, such as the protrusions 120 or other roughening surface technique, can be applied to limit movement of the strap 10 within the strap receipting opening 46.

As mentioned above, each of the couplers can either directly or indirectly connect to the attachment member. For an indirect connection, the intermediate adapter 130 can be used. As illustrated in FIG. 8, the intermediate adapter 130 includes an adapter body 132 extending between a connector 154 and a base 170 having similar configurations to the connector 54 and base 70 of the coupler 12 and the attachment member 14. The description of the connector 54 and the base 70 are also applicable to the connector 154 and the base 170 of the intermediate adapter 130. The adapter body 132 can be fabricated from a material similar to the strap 10 or alternatively can be formed of a less flexible material, such as material used to form the couplers 12, 12′ or the attachment member 14.

To manufacture the lanyard system, the strap 10 is welded to form the loop 22 prior to coupling the strap 10 and coupler 12 together. In another embodiment, the strap 10 is first threaded through the strap receiving opening 46 and then the loop 22 is formed by welding the together the first end portion 24, the second end portion 26, and the intermediate portion 28 of the strap 10 together. Additionally, or alternatively, the joint region 30 is provided closer to the proximal arm 20 of the coupler 12 so that the loop is tightly formed around the arm portion 50. In such an embodiment, the loop 22 of the strap 10 may be too small to be moved through the second opening portion 82 and from the coupler 12, thus securing the strap 10 to the coupler 12.

For example, in one embodiment, the strap 10 is welded to form the loop 22 of a first size. The arm portion 20 is then inserted through the loop 22, and then a second weld 30′ (FIG. 7) is formed just proximal to the arm portion 20, as described above, decreasing the size of the loop 22 to a size that more closely approximates a diameter of the arm portion 22. Also, for example, in one embodiment, the strap 10 is threaded through the strap receiving opening 46, before any welds are provided, and then a single weld 30 is provided just proximal to the proximal arm 20 of the coupler 12 so that a tight loop around the proximal arm 20 is formed. One will appreciate, from the embodiments described herein, that any number of joint regions can be formed along the length of the strap 10, proximal to the coupler 12, either before or after the strap 10 is secured within the strap receiving opening 46.

Generally, the strap, coupler, and the attachment member can each have a variety of sizes and shapes according to various implementations of the present disclosure. The dimensions noted herein are meant for illustrative purposes only and represent non-limiting examples of the various sizes of straps, couplers, and the attachment members that may be achieved or used. One skilled in the art will appreciate that a manufacturer can form the strap, coupler, and attachment member to have different sizes, shapes, configurations, and relative dimensions.

Additionally, the strap, coupler, and the attachment member can be fabricated from a variety of materials. For instance, and not by way of limitation, the coupler and attachment member can be molded or otherwise formed of various materials, including metals, plastics, rubbers, and other materials and manufacturing methods commonly known in the art. For instance, injection molding of DELRIN or CELCON plastic is one method for manufacturing the coupler and/or the attachments members. The materials and manufacturing methods that form the strap can include polyesters, nylons, cotton, or other natural or synthetic materials commonly used in the art. Ends of the strap can be rounded, square, or a variety of different shapes.

The articles “a,” “an,” and “the” are intended to mean that there are one or more of the elements in the preceding descriptions. The terms “comprising,” “including,” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements. Additionally, it should be understood that references to “one embodiment” or “an embodiment” of the present disclosure are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features. Numbers, percentages, ratios, or other values stated herein are intended to include that value, and also other values that are “about” or “approximately” the stated value, as would be appreciated by one of ordinary skill in the art encompassed by embodiments of the present disclosure. A stated value should therefore be interpreted broadly enough to encompass values that are at least close enough to the stated value to perform a desired function or achieve a desired result. The stated values include at least the variation to be expected in a suitable manufacturing or production process, and may include values that are within 5%, within 1%, within 0.1%, or within 0.01% of a stated value.

A person having ordinary skill in the art should realize in view of the present disclosure that equivalent constructions do not depart from the spirit and scope of the present disclosure, and that various changes, substitutions, and alterations may be made to embodiments disclosed herein without departing from the spirit and scope of the present disclosure. Equivalent constructions, including functional “means-plus-function” clauses are intended to cover the structures described herein as performing the recited function, including both structural equivalents that operate in the same manner, and equivalent structures that provide the same function. It is the express intention of the applicant not to invoke means-plus-function or other functional claiming for any claim except for those in which the words ‘means for’ appear together with an associated function. Each addition, deletion, and modification to the embodiments that falls within the meaning and scope of the claims is to be embraced by the claims.

The terms “approximately,” “about,” and “substantially” as used herein represent an amount close to the stated amount that still performs a desired function or achieves a desired result. For example, the terms “approximately,” “about,” and “substantially” may refer to an amount that is within less than 5% of, within less than 1% of, within less than 0.1% of, and within less than 0.01% of a stated amount. Further, it should be understood that any directions or reference frames in the preceding description are merely relative directions or movements. For example, any references to “up” and “down” or “above” or “below” are merely descriptive of the relative position or movement of the related elements.

The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes that come within the meaning and range of equivalency of the claims are to be embraced within their scope. 

1. A lanyard coupler for selective attachment to a lanyard strap and an attachment member, the lanyard coupler comprising: a body having a first end and a second end, an arm portion being formed toward the first end, the body tapering from the first end toward the second end; a strap receiving opening extending across a portion of the body; and a connector extending from the second end of the body.
 2. The lanyard coupler of claim 1, wherein the arm portion extends in a cantilever fashion.
 3. The lanyard coupler of claim 1, further comprising a chamfer or tapered edge along a perimeter of the lanyard receiving opening.
 4. The lanyard coupler of claim 1, further comprising a chamfer or tapered edge along a perimeter of the body.
 5. The lanyard coupler of claim 1, wherein the lanyard receiving opening comprises a first opening portion and a second opening portion, the first opening portion having a first terminal end having a generally curved profile and a second terminal end terminating toward the second opening portion.
 6. The lanyard coupler of claim 5, wherein the second opening portion extends angularly from the first opening portion.
 7. The lanyard coupler of claim 6, wherein the second opening portion comprises a first portion and a second portion, the first portion and the second portion being inclined relative to a longitudinal axis of the body at different inclinations.
 8. The lanyard coupler of claim 7, wherein the first portion extends from the first opening portion and the second portion extends from the first portion, the first portion being generally parallel to the longitudinal axis and the second portion being transverse to the longitudinal axis.
 9. The lanyard coupler of claim 1, wherein the arm portion is connected to a body portion at a first side of the body and separated at a second side of the body.
 10. The lanyard coupler of claim 9, wherein the arm portion has a generally gooseneck shape with a hook portion at the second side.
 11. The lanyard coupler of claim 10, wherein the hook portion comprises at least one lip adjacent a junction of a first portion and a second portion forming the lanyard receiving opening.
 12. The lanyard coupler of claim 11, wherein the at least one lip extends towards the first side of the body.
 13. The lanyard coupler of claim 11, wherein the second portion is narrower adjacent the at least one lip than at a terminal end of the lanyard receiving opening at the first side of the body.
 14. The lanyard coupler of claim 1, wherein the body comprises an enlarged portion adjacent the connector, the enlarged portion being curved in a direction transverse to an axis of the body extending from the first end to the second end.
 15. The lanyard coupler of claim 1, wherein the body comprises a roughened surface surrounding the lanyard receiving opening. 16.-20. 